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Home >> GMC >> 2002 >> Jimmy 2D Utility, Part Time, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Engine Exhaust System >> Repair Instructions >> Exhaust Manifold Replacement >> Removal Procedure

Removal Procedure

  1. Disconnect the battery negative cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE .
  2. Raise the vehicle. Refer to LIFTING & JACKING THE VEHICLE in General Information.
  3. Remove the drive belt. Refer to Drive Belt Replacement .
  4. Remove the exhaust pipe from the exhaust manifold. Refer to Exhaust Manifold Pipe Replacement .
  5. Lower the vehicle.
  6. Remove the upper fan shroud. Refer to FAN SHROUD REPLACEMENT in Engine Cooling.
    IMPORTANT: Do not evacuate the air conditioning system.
  7. Remove the air conditioning compressor, if equipped, and set it aside. Refer to COMPRESSOR in Heating, Ventilation and Air Conditioning.
  8. Remove the power steering pump and set it aside, using the following procedure:
    Fig 1: Power Steering Pump Bolts And Studs
    G01660136Courtesy of GENERAL MOTORS CORP.
    1. 8.1. Two nuts from the cylinder head studs
    2. 8.2. One bolt from the rear bracket
    3. 8.3. Three bolts from the front of the power steering pump

      The bolts are accessible through the holes in the power steering pump pulley.

  9. Remove the oil level indicator tube. Refer to OIL LEVEL INDICATOR AND TUBE REPLACEMENT .
  10. Disconnect the oxygen sensor electrical connection.
    11. Fig 2: Exhaust Manifold Oxygen Sensor Electrical Connection
    G01660137Courtesy of GENERAL MOTORS CORP.
  11. Remove the oxygen sensor from the exhaust manifold to prevent damage to the sensor.
    12. Fig 3: Exhaust Manifold Oxygen Sensor
    G01660138Courtesy of GENERAL MOTORS CORP.
  12. Remove the air injection nuts (1, 2).
    13. Fig 4: Air Injection Nuts
    G01660139Courtesy of GENERAL MOTORS CORP.
  13. Remove the air injection pipe from the exhaust manifold.
  14. Remove the exhaust manifold nuts.
    15. Fig 5: Exhaust Manifold Nuts
    G01660140Courtesy of GENERAL MOTORS CORP.
  15. Remove the exhaust manifold.
  16. Remove the exhaust manifold gasket.
  17. Remove the heat shield, if replacing the exhaust manifold.
    18. Fig 6: Exhaust Manifold Heat Shield
    G01660141Courtesy of GENERAL MOTORS CORP.
  18. Clean all sealing surfaces. Refer to EXHAUST MANIFOLD CLEANING AND INSPECTION in Engine Mechanical - 2.2L Unit Repair.
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